Gas fired cooktop and method of assembling the same

ABSTRACT

A gas burner assembly for a gas fired cooktop includes a first burner, second burner and a third burner arranged between the first burner and second burner. A first valve is configured to control gas supplied to the first burner. A second valve is configured to control gas supplied to the second burner and the third burner and distribute a first portion of gas to the second burner and a second portion of gas to the third burner.

BACKGROUND OF THE INVENTION

This invention relates generally to gas cooking appliances, and, more specifically, to a gas burner assembly for a gas fired cooktop.

Gas fired stoves, ovens, and ranges typically include one or more gas heating elements coupled to a main gas line on the appliance that provides fuel to the heating elements, sometimes referred to as burners. In a domestic range, a gas line is connected to a distribution manifold within the appliance to direct gas to a plurality of surface burner elements on a cooktop, or to baking elements within an oven cavity. Operation of the burners and cooking elements is usually accomplished with burner control knobs mounted on the front wall of the appliance in front of the cooktop. When the control knobs are actuated, fuel is supplied to associated heating elements, and an ignition module creates a spark to ignite the gas, thereby producing a flame.

Known gas ranges generally do not have separate heating zones. To improve the performance of the gas range, an improved gas range has been developed with separate heating zones which are effective for heating large griddles. However, such gas ranges do not have a single zone presenting a heat source in substantially round presentation. Accordingly, the gas range does not perform well on routine cookware. In addition, the separate heating zones got this type of gas range generally use or share a multi-staged manual proportional valve which has very poor user control/resolution, because the working range is simply divided in half.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a gas burner assembly for a gas fired cooktop is provided. The gas burner assembly includes a first burner and a second burner. A third burner is arranged between the first burner and second burner. A first valve is configured to control gas supplied to the first burner, and a second valve is configured to control gas supplied to the second burner and the third burner and distribute a first portion of gas to the second burner and a second portion of gas to the third burner.

In another aspect, a gas fired cooktop is provided. The gas fired cooktop includes a body, a first burner, and a second burner. A first valve is configured to control gas supplied to the first burner. The gas fired cooktop includes a third burner having a first end, a second end, and a middle portion. The first end of the third burner is adjacent the first burner, and both of the first end and second end are narrower than the middle portion. The third burner is configured to remain outside a flame path of the first and second burners.

In still another aspect, a method for assembling a gas fired cooktop is provided. The method includes providing a body, providing a first burner and a second burner coupled to the body, and providing a first valve configured to control gas supplied to the first burner. The method also includes providing a third burner arranged on the body between the first burner and the third burner. The method further includes providing a second valve configured to control gas supplied to the second burner and the third burner and distribute a first portion of gas to the second burner and a second portion of gas to the third burner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary free standing gas range;

FIG. 2 is a perspective view of an exemplary cooktop for the gas range shown in FIG. 1;

FIG. 3 is a perspective view of a cooktop according to another embodiment of the invention;

FIG. 4 is a schematic, top view of a gas burner on the cooktop shown in FIG. 3 coupled to a gas valve assembly; and

FIG. 5 is a side elevational schematic view of the gas range shown in FIG. 1 partly broken away.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a gas cooking appliance in the form of a free standing gas range 10 including an outer body or cabinet 12 that incorporates a generally rectangular cooktop 14. An oven, not shown, is positioned below cooktop 14 and has a front-opening access door 16. A range backsplash 18 extends upward from a rear edge 20 of cooktop 14 and includes, for example, a control display and control selectors (not labeled) for user manipulation to select operative oven features, cooking timers, time and temperature displays, etc. It is contemplated that the present invention is applicable, not only to cooktops which form the upper portion of a range, such as range 10, but to other forms of cooktops as well, such as, but not limited to, built-in counter units that are mounted to kitchen counters. Therefore, gas range 10 is provided by way of illustration rather than limitation, and accordingly there is no intention to limit application of the present invention to any particular appliance or cooktop, such as range 10 or cooktop 14. In addition, it is contemplated that the present invention is applicable to multiple fuel cooking appliances, e.g., a gas cooktop with an electric oven or other combinations of heating elements.

FIG. 2 is a perspective view of cooktop 14 for gas range 10 shown in FIG. 1. In an exemplary embodiment, cooktop 14 includes a body 22, six gas fueled burners 24, 26, 28, 30, 32, and 34 arranged on body 22, and a grate frame 36 positioned over burners 24, 26, 28, 30, 32, and 34. Body 22 has an upper surface 38, and a recessed area 40 is defined on upper surface 38. Specifically, recessed area 40 is positioned below upper surface 38 of cooktop 14, and is surrounded by a front wall 42, a back wall 44, and two side walls 46, 48. As such, recessed area 40 serves to catch spills from cooking utensils (not shown) being used with cooktop 14. In one embodiment, front wall 42 is adjacent a cooking area configured to be utilized by an operator when manipulating gas range 10.

In the exemplary embodiment, burners 24, 26, 28, and 30 are substantially circular in shape, and are positioned on recessed area 40. Specifically, burners 24, 28, and 32 are positioned adjacent sidewall 46, thereby forming a first gas burner set 50. Gas burners 26, 30, and 34 are positioned adjacent side walls 48 of cooktop 14, thereby forming a second gas burner 52. For consistency, burners 24, 28, 32 are referred to as a first burner 24, a second burner 28, and a third burner 32. Likewise, burners 26, 30, 34 are referred to as a fourth burner 26, a fifth burner 30, and a sixth burner 34. In the exemplary embodiment, burner 32 has an elongated shape, such as a rectangular shape, or an oval shape, which may be configured for griddle use, and is positioned between first burner 24 and second burner 28. Sixth burner 34 has substantially the same structure with third burner 32, and positioned between fourth burner 26 and fifth burner 30.

In the exemplary embodiment, grate frame 36 substantially spans cooktop 14, and includes a left grate section 60, a right grate section 62, and a spaced middle section 64 positioned between and adjacent grate sections 60, 62. In use, grate section 60 overlies burner pair 24, 28 and 32. Grate section 62 overlies burner pair 26, 30, and 34.

In the exemplary embodiment, grate sections 60 and 62 are similarly constructed and each section 60, 62, and 64 includes a plurality of exterior frame elements 66. At least one interior frame element 68 extending between exterior frame elements 66. As used herein, “interior” and “exterior” refer to relative positions in the overall grate frame 36 with exterior referring to outer edges of the overall grate frame 36 and interior referring to elements extending from and/or between outer edges of grate frame 36.

In the exemplary embodiment, each section 60, 62 further includes a plurality of utensil supporting fingers 72 extending inwardly from frame elements 66, 68 and toward the corresponding burners 24, 26, 28, 30, 32, and 34, respectively. Each finger 72 includes a substantially flat top surface 74 to support cooking utensils and implements (e.g., pots and pans) thereon, and top surfaces 74 of fingers 72 on the same grate section are substantially coplanar with respect to each other. It is recognized, however, that the configuration and arrangement pattern of the fingers and interior frame elements could be varied in alternative embodiments of the invention.

In the exemplary embodiment, and as illustrated in FIG. 2, when grate frame 36 is employed on cooktop 14, interior frame elements 68 of grate sections 60, 62 are adjacent interior frame elements 68 of middle section 64. Lateral exterior frame elements 66 of middle section 64 are generally aligned with lateral exterior frame elements 66 of grate sections 60, 62.

Supporting fingers 72 are elevated from exterior and interior frame elements 66, 68. Thus, when exterior frame elements 66 of sections 60, 62, and 64 are placed on cooktop 14, fingers 72 and interior frame elements 68 extend above cooktop 14 and above burners 24, 26, 28, 30, 32, and 34. In addition, support fingers 72 include generally coplanar top surfaces. As such, grate frame 36 provides a utensil supporting surface 78 over cooktop 14 and defined by top surfaces 74, 76 of fingers 72. The cooking utensils may be placed on utensil supporting surface 78, and further be slid across utensil supporting surface 78 to any desired position on utensil supporting surface 78 without lifting the utensils.

FIG. 3 is a perspective view of a cooktop 100 according to another embodiment of the invention. Cooktop 100 has one set of gas burners 102 including a first round burner 104, a second round burner 106, and an elongated, oval-shaped burner 108 positioned between first burner 104 and second burner 106. Gas burners 102 are similar to first gas burner set 50 and second gas burner set 52 (shown in FIG. 2) except that three burners 104, 106, 108 are aligned with each other along a direction perpendicular to the direction along which burners 24, 28, 32 are aligned with each other (shown in FIG. 2). More details of gas burners 102 are described hereinafter. It is to be noted that first gas burner set 50 and second gas burner set 52 of cooktop 14 (shown in FIG. 2) include all of the features that gas burners 102 have.

First burner 104 is positioned in recessed area 40 of left grate section 60, and second burner 106 is positioned in recessed area 40 of right grate section 62. In addition, third burner 108 is located in recessed area 40 of spaced middle section 64. More particularly, each of burners 104, 106, 108 is surrounded by supporting fingers 72 to support cooking utensils and implements (e.g., pots and pans) thereon. In the exemplary embodiment, first and second round burners 104, 106 are suitable for a specific shape of utensil, such as, round pots. Third burner 108 is for a specific shape of utensil, such as, frying pans.

FIG. 4 is a schematic, top view of gas burners 102 coupled to a motorized gas valve assembly 110. As described above, third burner 108 is positioned between first burner 104 and second burner 106. First burner 104, second burner 106, and third burner 108 are in a linear arrangement. Third burner 108 has a low profile and a thickness between about 0.55 and 0.70 inches. For example, one preferred thickness of third burner 108 is 0.65 inches. While the first and second burners 104, 106 have a profile relatively higher than the third burner 108. More particularly, the thickness of first and second burners 104, 106 is higher than third burner 108 for a limited value, for example, ranged between 0.20 and 0.25 inches.

Third burner 108 includes a first end 112, a second end 114, and a middle portion 116. More particularly, first end 112 and second end 114 are narrower than middle portion 116. Both ends 112, 114 narrow gradually to a point. First end 112 is positioned adjacent to first burner 104, and second end 114 is positioned adjacent to second burner 106. Both ends 112, 114 are configured to remain outside of a flame path of first burner 104 and second burner 106, such that third burner 108 will not impact the performance of first and second burners 104, 106.

Middle portion 116 includes a first side 118 and a second side 120 along a longitudinal direction, and a plurality of main gas ports 122 are defined through two sides 118, 120 thereby forming a central flame area in middle portion 116. In the exemplary embodiment, a plurality of smaller gas ports 124 are defined through first end 112 and second end 114. With first end 112 and second end 114 of third burner 108 positioned adjacent first and second burners 104, 106, third burner 32 can be lit by at least one of first burner 104 and second burner 106 when gas is supplied to third burner 108 and at least one of first burner 104 and second burner 106 is lit. More particularly, when one of first and second burners 104, 106 is supplied with gas and ignited a flame is obtained which introduces flame to smaller gas ports 124 and further to main gas ports 122 as third burner 108 is supplied with gas at the same time.

Gas valve assembly 110 includes a first valve 126 utilized to control gas supplied to first burner 104. A second valve 128 is utilized to control gas supplied to second burner 106 and third burner 108, and distribute a first portion of gas to second burner 106 and a second portion of gas to third burner 108. More specifically, if second valve 128 is opened to different levels, different amounts of gas are distributed to burners 106, 108. As such, heat produced by burners 106, 108 is adjusted through second valve 128.

In one embodiment, second valve 128 allows the gas to be supplied to second burner 106 in a steady stream and is capable of varying the supply of gas to third burner 108. Alternatively, the amount of gas supplied to second burner 106 and third burner 108 varies with octuation of valve 128. Gas valve assembly 110 also includes a third valve 130 arranged between second valve 128 and third burner 108. Third valve 130 is used as an on/off valve to allow or prohibit gas to flow to burner 108. When third valve 130 is off, second valve 128 only controls the gas supplied to second burner 106 while third burner 108 is not in use. Please note that gas valve assembly 110 is also applicable to cooktop 14 (shown in FIG. 2) to control gas supplied to one of first gas burner set 50 and second gas burner set 52. In one embodiment, another gas valve assembly (not shown) is employed in cooktop 14 of gas range 10 to control gas supplied to the other one of first gas burner 48 and second gas burner set 52.

FIG. 5 is a side elevational schematic view of gas range 10 (shown in FIG. 1) partly broken away, which shows also first gas burner set 50. Gas range 10 is mounted adjacent a kitchen wall 132 and incorporates motorized gas valve assembly 110 therein to control supplied gas. Gas burner 24 of first gas burner set 50 is connected by a gas line 134 to a main gas line 136, and first valve 126 of gas valve assembly 110 is arranged between first gas burner 24 and main gas line 136 to control gas supplied to first gas burner 24. Second gas burner 28 is provided with gas through a first manifold 138, and third burner 32 is provided with gas through a second manifold 140. Both first manifold 138 and second manifold 140 are in flow communication with a gas line 142 to main gas line 136. Second valve 128 is operatively coupled to gas line 142 to distribute a first portion of gas to second burner 28 and a second portion of gas to third gas burner 32. Third valve 130 is positioned between third burner 32 and second valve 128, as described above.

When motorized lockout valve assembly 110 is in an open position, gas flow is unimpeded through gas line 142 to manifolds 138, 140, to burners 28, 32, and through gas line 134 to burner 24 when range 10 is actuated. When motorized gas valve assembly 110 is in a closed position, gas flow is prevented from flowing through gas line 134 and gas manifolds, 138, 140 from gas line 142, thereby blocking gas flow to burners 24, 28, 32. Burners 24, 28, and 32 (as well as burners 26, 30, and 34 shown in FIG. 2) are thereby inoperative and gas flow is avoided.

The utilization of the above described gas valve assembly allows the gas burners to have their heat adjusted simultaneously. In addition, the elongated oval shape of the third burner allows a specific shape of pots and pans to be heated efficiently. Third burner can be lit by at least one of the round first and second burners and it does not interfere with the performance of the first and second burners, as third burner remains outside of a flame path of the first and second burners. The third valve connects between the second valve and the third burner, which the allows burners to perform like a standard cook top, having the round burners for round pots operating independently.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. 

1. A gas burner assembly for a gas fired cooktop comprising: a first burner and a second burner; a third burner arranged between said first burner and second burner; each said burner comprising a separate body; a first valve configured to control gas supplied to said first burner; and a second valve configured to control gas supplied to said second burner and said third burner and distribute a first portion of gas to said second burner and a second portion of gas to said third burner.
 2. A gas burner assembly in accordance with claim 1 wherein a third valve is arranged between said second valve and said third bumer, said third valve configured as an on/off valve to allow or prohibit gas to flow to said third burner.
 3. A gas burner assembly in accordance with claim 1 wherein said second valve allows said second burner and said third burner to have their heat adjusted simultaneously.
 4. (canceled)
 5. A gas burner assembly in accordance with claim 1 wherein said third burner includes a first end, a second end, and a middle, said ends narrower than said middle.
 6. A gas burner assembly in accordance with claim 5 wherein said middle comprises a plurality of main gas ports and said ends comprise a plurality of smaller ports.
 7. A gas burner assembly in accordance with claim 1 wherein said third burner configured to remain outside of the flame path of said first burner and said second bumer.
 8. A gas burner assembly in accordance with claim 1 wherein said third burner configured to be lit by at least one of said first burner and said second burner when gas is supplied to said third burner and at least one of said first burner and said second burner.
 9. A gas fired cooktop comprising: a body; a first burner and a second burner; a first valve configured to control gas supplied to said first burner; a third burner having a first end, a second end, and a middle, said first end adjacent said first burner, said ends narrower than said middle, and said third burner configured to remain outside of a flame path of said first and second burners.
 10. A cooktop in accordance with claim 9 further comprising a second valve configured to control gas supplied to said second burner and said third burner and distribute a first portion of gas to said second burner and a second portion of gas to said third bummer.
 11. A cooktop in accordance with claim 9 wherein said third burner includes a central flame area in said middle.
 12. A cooktop in accordance with claim 11 wherein said central flame area comprises a first side and a second side along a longitudinal direction, a plurality of main ports are defined through at least one of said first and second sides thereby forming a flame zone around said third burner.
 13. A cooktop in accordance with claim 9 wherein said body further comprises a front wall, a back wall, two side walls, and a top recessed area surrounded by said walls, said burners positioned on said recessed area.
 14. A cooktop in accordance with claim 9 further comprising a third valve between said second valve and said third burner, said third valve configured as an on/off valve to allow or prohibit gas flow to said third burner.
 15. A method of assembling a gas fired cooktop, said method comprising: providing a gas burner assembly including a first bumer, a second burner and a third burner arranged between the first burner and the second burner, each of the burners comprising a separate body; providing a first valve configured to control gas supplied to the first burner; providing a second valve configured to control gas supplied to said second burner and said third burner, and distribute a first portion of gas to said second burner and a second portion of gas to said third burner.
 16. A method in accordance with claim 15 wherein said providing a third burner comprises configuring said third burner to remain outside a flame path of said first and second burners.
 17. A method in accordance with claim 15 wherein said providing a third burner comprises configuring said third burner such that it can be lit by at least one of said first burner and said second burner.
 18. A method of assembling a gas fired cooktop in accordance with claim 15 further comprising arranging a third valve between the second valve and the third burner, the third valve configured as an on/off switch to allow or prohibit gas to flow into the third bumer.
 19. A method in accordance with claim 15 wherein said providing a third burner comprises providing a burner having a first end, a second end and a middle, said ends narrower than said middle, at least one of said ends adjacent one of said first burner and said second bumer.
 20. A method in accordance with claim 19 further comprising defining a plurality of ports through the third burner between ends of the burner.
 21. A gas burner assembly for a gas fired cooktop comprising: a first burner and a second burner; a third burner arranged between said first burner and second burner; each said burner comprising a separate body; a first valve configured to control gas supplied to said first bumer; and a second valve configured to control gas supplied to said second burner and said third burner and distribute a first portion of gas to said second burner and a second portion of gas to said third burner, said third burner configured to remain outside of the flame path of said first burner and said second bumer, said third burner configured to be lit by at least one of said first burner and said second burner when gas is supplied to said third burner and at least one of said first burner and said second burner. 